This application claims the benefit of Korean Patent Application No. 2003-89156, filed Dec. 9, 2003, the contents of which are hereby incorporated herein by reference in their entirety.
1. Technical Field
The present invention relates to a method of fabricating a semiconductor device and a semiconductor device fabricated thereby, and more particularly, to a method of fabricating a flash memory device and a flash memory device fabricated thereby.
2. Discussion of the Related Art
A flash memory device is a non-volatile memory device capable of erasing or programming information electrically, and is widely used as a memory device of electronic appliances such as computers, digital cameras, or the like. The flash memory device has two gates, that is, a floating gate used as a charge storage layer, and a control gate for controlling input and output signals. Further, in accordance with the structures of the floating gate and the control gate, it can be classified as a stack gate flash memory device or a split gate flash memory device.
The fabrication of a highly-integrated semiconductor device having a stack structure involves a number of photolithography processes. However, with the increased demand in high integration of semiconductor devices, the photolithography process requires solutions to solve the limitation of resolution and interlayer misalignment. For example, in the process of forming a floating gate of the flash memory device, the floating gate needs to be exactly aligned to the active region of the semiconductor substrate. However, as described above, it is difficult to form a floating gate of a desired shape due to the limitation of the photolithography process, and furthermore, there may occur a misalignment with an active region under the floating gate. Because of this, there occurs a problem of deteriorating the cell characteristics in each cell of the flash memory device, i.e., a length of a channel under the floating gate is short, or the channel is not generated at all. As efforts to overcome the problems, various methods have been introduced to align the floating gate with the active region of the semiconductor substrate.
A method of fabricating a conventional flash memory device to form a self-aligned floating gate on the active region of the semiconductor substrate is disclosed in U.S. Pat. No. 6,627,942.
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As described above, in the method of fabricating a conventional flash memory device, a self-aligned floating gate can be formed in the active region. However, a problem may be caused in a subsequent process of forming an oxide layer in the method described as above. For example, in the method of fabricating a split gate flash memory device, a polysilicon oxide layer is formed on the polysilicon layer pattern 108 by a thermal oxidation process after forming the polysilicon layer pattern 108. During the process, an interface B between the isolation layer 104 and the polysilicon layer pattern 108 can be used as a diffusion path of oxygen. As a result, there may occur a smile effect in which a thickness of the gate oxide layer 106 adjacent to the interface B is thick. By the smile effect, since the thickness of the gate oxide layer 106 is non-uniform, the electrical characteristics of each cell of the split gate flash memory device may be deteriorated.
Therefore, one feature of the present invention is to provide a method of fabricating a flash memory device for avoiding non-uniform thickness of a gate oxide layer under a floating gate when forming a self-aligned floating gate on an active region of a semiconductor substrate.
Another feature of the present invention is to provide a flash memory device fabricated by the method of fabricating a flash memory device.
In one aspect, the invention is directed to a method of fabricating a flash memory device. In accordance with the method of the invention, an isolation layer defining an active region in a semiconductor substrate is formed. The isolation layer is formed to have a protrusion higher than a top surface of the active region, and to provide a groove in the active region. A conductive layer pattern is formed in the groove. A buffer layer is formed on the semiconductor substrate having the conductive layer pattern. An oxidation barrier layer pattern having a line-shape opening across the active region is formed on the buffer layer. The buffer layer and an upper portion of the conductive layer pattern, which are exposed by the opening, are selectively oxidized to form a mask oxide layer at a cross region of the opening and the active region, and simultaneously to form a buffer oxide layer on the isolation layer adjacent to the mask oxide layer. The oxidation barrier layer pattern is removed. Using the mask oxide layer, the buffer oxide layer and the isolation layer as etch masks, the buffer layer and the conductive layer pattern are etched, so as to form a floating gate on the active region.
In one embodiment, the isolation layer is formed with shallow trench isolation (STI) structure.
The method can further include forming a gate oxide layer on the active region after forming the isolation layer.
The conductive layer pattern can be formed of polysilicon.
In one embodiment, forming the conductive layer pattern comprises: forming a conductive layer on the semiconductor substrate having the isolation layer; and performing CMP on the conductive layer to expose the isolation layer. In one embodiment, the conductive layer is formed of polysilicon.
In one embodiment, forming the conductive layer pattern comprises: forming a conductive layer on the semiconductor substrate having the isolation layer; and performing an etch back process on the conductive layer to expose an upper surface of the isolation layer and simultaneously to form the conductive layer pattern on the active region, wherein the etch back process is performed such that an upper surface of the conductive layer pattern is lower than the upper surface of the isolation layer, and has a recessed profile. The conductive layer can be formed of polysilicon.
In one embodiment, forming the conductive layer pattern comprises: forming a conformal first conductive layer on the entire surface of the semiconductor substrate having the isolation layer; performing an etch back process on the conductive layer to form conductive layer spacers covering sidewalls of the protrusion of the isolation layer; forming a conformal second conductive layer on the entire surface of the semiconductor substrate having the conductive layer spacers; and performing a CMP or etch back process on the second conductive layer to expose the isolation layer. The first and the second conductive layers can be formed of polysilicon.
In one embodiment, the buffer layer is formed of a polysilicon layer.
In one embodiment, the oxidation barrier layer pattern is formed of a silicon nitride layer.
In one embodiment, forming the oxidation barrier layer pattern comprises: forming an oxidation barrier layer on the buffer layer; forming a photoresist pattern on the oxidation barrier layer, wherein the photoresist pattern has an opening across the active region with a line shape; and etching the oxidation barrier layer using the photoresist pattern as an etch mask. The oxidation barrier layer can be formed of a silicon nitride layer.
In one embodiment, the method further comprises: forming an inter-gate dielectric layer at least covering the exposed sidewalls of the floating gate after forming the floating gate; and forming a control gate on the resultant structure having the inter-gate dielectric layer, to overlap at least one side portion of the floating gate, and to cross the active region.
In accordance with another aspect, the invention is directed to a flash memory device. The flash memory device includes an isolation layer disposed in a semiconductor substrate to define an active region, wherein the isolation layer has a protrusion higher than the surface of the semiconductor substrate to provide a groove in the active region. A floating gate is disposed to have a recessed upper surface in the groove. A mask oxide layer is disposed on the floating gate aligned to the floating gate. A buffer oxide layer is disposed on the isolation layer connected to the mask oxide layer.
In one embodiment, the floating gate is a polysilicon layer.
In one embodiment, the mask oxide layer and the buffer oxide layer are polysilicon oxide layers.
The flash memory device can further comprise a gate oxide layer interposed at least between the floating gate and the semiconductor substrate of the active region.
The flash memory device can further comprise: an inter-gate dielectric layer at least covering sidewalls of the floating gate; and a control gate disposed across the active region, to overlap at least one-side portion of the floating gate.
The foregoing and other objects, features and advantages of the invention will be apparent from the more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. In the drawings, the thickness of layers and regions are exaggerated for clarity.
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For example, the silicon nitride layer may be formed of an LPCVD method using dichlorosilane (SiCl2H2) and ammonia (NH3) as a reactant gas. Then, a photoresist pattern 316 is formed on the oxidation barrier layer 314. The photoresist pattern 316 is formed to have opening in line shape across the active region 302.
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According to the embodiments of the present invention, as described above, the conductive layer patterns 310 are formed self-aligned on the active region 302. Then, after the mask oxide layer 318a is selectively formed in upper portion of the conductive layer patterns 310, there is formed a floating gate 320 being self-aligned to the mask oxide layers 318a. Therefore, the split gate flash memory device according to the embodiments of the present invention has the self-aligned floating gate 320 on the active region 302, thereby solving the problem caused by a misalignment of the floating gate 320. Further, the buffer layer 312 is formed the conductive layer pattern 310 and the isolation layer 304, thereby preventing a phenomenon that the gate oxide layer 308 is locally thick during the formation process of the mask oxide layer 318a.
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An isolation layer 304 defining an active region 302 is disposed in a semiconductor substrate 300. The isolation layer 304 has a protrusion higher than the surface of the semiconductor substrate. A groove 306 is defined over the active region 302 by the protrusions of the isolation layer 304. A floating gate 320 with a recessed upper surface is disposed in the groove 306. The floating gate 320 may be a polysilicon layer. A gate oxide layer 308 is interposed between at least the floating gate 320 and the semiconductor substrate of the active region 302. On the floating gate 320, there is disposed a mask oxide layer 318a aligned to the floating gate 320. Further, a buffer oxide layer 318b is disposed on the isolation layer 304 adjacent to the mask oxide layer 318a, connected to the mask oxide layer 318a. In the embodiment of the present invention, the mask oxide layer 318a and the buffer oxide layer 318b may be polysilicon oxide layers. Further, there is formed an inter-gate dielectric layer 322 for covering the exposed sidewalls of at least the floating gate 320. The inter-gate dielectric layer 322 may be a thermal oxide layer. A control gate 324 is formed to overlap at least one side portion of the floating gate 320, across the active region 302. The control gate 324 may be a polysilicon layer.
As described above, according to the present invention, a flash memory device can be provided to prevent a thickness of the gate dielectric layer under the floating gate being non-uniform when forming the self-aligned floating gate on the active region. Further, since the floating gate is formed to have sharp sidewall tips, a flash memory device can be provided with improved erasing characteristics.
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
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10-2003-0089156 | Dec 2003 | KR | national |
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